Disco rebuild project

mrnice said:

Bloody good stuff that fertan! I must have gone through litres of that stuff when I did mine, keep up the good work itll all be worth it in the end

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Cheers pal, never used Fertan before but it gets good reviews so I thought it was worth a try

THE BUDDAH said:

Hi Rob,
You deserve a pat on the back as it's a lot of work...all for the love of it....lol
Well done.

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Thanks Mike, it feels like the right thing to do as any Disco of this age will potentially need some of this work doing any way so better to stick with the one I know

Paulmitchell1984 said:

looking good, will be watching this as i think mine will need doing soon, hopefully not to that extent, will find out when i take wing off for snorkel

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Trust me I have done patches before that just haven't lasted so decided for the cost of replacing the wing it would give me so many more years of life. Good luck with yours mate

Hi Rob,

All said and done,
When you have finished the work is your car going to stay on the road or will you be taking it off road?

THE BUDDAH said:

Hi Rob,

All said and done,
When you have finished the work is your car going to stay on the road or will you be taking it off road?

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Its a weekend off road toy so will be getting muddy again when its finished.

RobP said:

Its a weekend off road toy so will be getting muddy again when its finished.

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Yea same here, i'd like to get some green lane driving in once it's all done and combine it with a bit of camping.

Good work mate I'll be keeping an eye on this thread, I would love to do this to my disco but time, money and the wife are stopping me lol!!

Will be worth it all in the end as you will have one tidy solid truck in the end, keep the updates comeing please m8 well done top job ;-)

Quite a job you got on there . Am interested to know why you changed from 10" rims (1st photo) to 7" rims (3rd photo) were there issues with the 10s? The reason I ask is am about to fit 10s to my truck. Good luck with the rest of your rebuild.

loose unit said:

Quite a job you got on there . Am interested to know why you changed from 10" rims (1st photo) to 7" rims (3rd photo) were there issues with the 10s? The reason I ask is am about to fit 10s to my truck. Good luck with the rest of your rebuild.

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Hi. Thanks for the comments.

When I first got the motor it had those wheels on they where hangkook dynapro MT 33/12.5/15's and I really hated the way it drove. It felt like I was driving on balloons and when the mud got sticky they seemed to sit on top of the mud instead of cutting through to find grip.

I ended selling them and fitting some second hand Grizzly Claws and then after a few years running them went for the Maltesa Kaimans in 265/75/16 fit and have been really pleased with them

Very good mate. I'm patching my v8 at the moment, spent money on bushes, suspension and other bits.

Weekend update...

The weather held out long enough today for me to make some progress.

Finished painting chassis rail

Light box / body mount bolted back on. Plug welded, dressed back and sprayed with Zinc rich primer


New inner wing clamped into position



Found this is a really good way to clean up plug weld holes prior to welding




Top rail plug welded into place




Dressed welds with flap disc and primed with zinc primer




Autobox oil cooler bolted back in place



Looking a bit healthier now


Rain stopped progress at this point so packed up

you are doing a great job mate

basher79 said:

you are doing a great job mate

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Thanks, its getting there but it does take a while

Fantastic photographs, looks like you're doing a great job!

Looking very good, Rob, thanks for posting and making ****ty work look interesting!!

PS, I don't mean your work is ****ty, I mean the job of removing wings/panels etc ...

_colin_ said:

Fantastic photographs, looks like you're doing a great job!

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Cheers Colin, Never done this amount of structual work before so its a learning experience. As they say life is a discovery!

Paul D said:

Looking very good, Rob, thanks for posting and making ****ty work look interesting!!
PS, I don't mean your work is ****ty, I mean the job of removing wings/panels etc ...

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Thnaks Paul, I know it's not going to be the most glamorous thread on the forum but when I was searching for info I couldn't find the detail I wanted so thought I would try to capture the detail for anyone else that wants to have a go themselves

doing a great job there m8, reminds me of when i did mine a few years back - wish id thought of cleaning up the chasis then.
keep up the thread + pics

doing a proper job matey, keep the pics coming!!

trax99 said:

doing a great job there m8, reminds me of when i did mine a few years back - wish id thought of cleaning up the chasis then.
keep up the thread + pics

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Well I only intend to do this once so thought I would try and do as much as possible as I went

Matt Baxter said:

doing a proper job matey, keep the pics coming!!

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Cheers Matt

Picked up one of those pop up gazebo's this week so I can try and get some more done this weekend even if it rains. Will do more pics this weekend as I go

Update.... The weather held so made some progress

Onto the home straight for this stage now.....
Support bar plug welded and dressed back



Zinc Primed


Brake pipe bracket fitted


All joints seam sealed



Another coat of primer on top



Brake pipe back on


Gave the whole lot several coats of gloss black




Battery tray and expansion bottle in


Washer reservoir and winch solenoid in


300 shape headlamps on though not sure about the fixing at the moment


Range rover tailgate gas struts for the bonnet


Feel like something is missing here??


Wings back on and re sprayed grill fitted


Even fitted a new black/silver LR badge normally fitted to supercharged Range Rovers


Thanks for all the comments so far.
I won’t be doing any more for a few weekends but will be making a start on the sills next.

nice work

Great work gives me ideas lol